Synopsis:

After more than 18 years of successful operation of a Submerged Arc Welding Fluxes manufacturing facility (SILICO PRODUCTS)  in Mumbai, India; supplying custom designed products to, amongst others,  Esab India, Advani-Oerlikon & Sudometal; for use in fabrication of oil & gas pipelines, gas cylinders, pressure vessels & re-surfacing of mining & material handling equipment, we bring our expertise in process optimization & implementation of First time Right manufacturing methodologies to North America. This is a surefire way of reducing operating costs & increasing profitability by targeting unseen wastes (such as rejected material, unplanned breakdowns) in productivity. It eliminates drastic actions such as retrenchment or other production scale backs.

Irrespective of the industry,  our data collection & statistical analysis methodology coupled with our tried & tested Lean production management protocols has many cross platform applications that can add value to your manufacturing goals & make your product very competitive.

Core Projects Executed:

Formulated & Optimized Submerged arc welding fluxes.

Provided project engineering, equipment specification layout & cost estimation for manufacture of Mold/Refining Fluxes (used in Continuous Casting of Steel).

Optimized EAF (electric arc furnace) operations for the manufacture of submerged arc welding (SAW) fluxes. Eliminated product variation & increased quantum of sell able product by 30%.

Optimized welding processing parameters for spiral welding of SAW pipes. Reduced re-work by 50%.

Optimized Surfacing/Overlaying parameters of:

(A) Pipe internals for applications in the Oil & Gas & Power industries. Improved product abrasion & chemical resistance.

(B) Repair & re-surfacing of worn out mining & material handling equipment. Formulated custom alloy fluxes for use with solid electrodes attaining a hardness of 55 Rc. The requirement  of expensive flux cored was eliminated. Improved product life cycle by 6 months as compared to original equipment.

Optimized operation of Rotary Kilns (similar to cement kilns) , for the manufacture of Sponge Fe. Specified & installed refractory ramming masses that were resistant to chemical attack & thermal shock. Incorporated an in situ pressure debris removal system. Resolved continuous break down due to material accretion & improved designed throughput by 12%. Overall production was increased by 30% & unplanned breakdowns eliminated.

Optimized operation of grinding circuit (Crushers, Grinders, Sieve decks, conveyors & cyclonic dust collectors) & reduced product variation by 30%.

Our Business

Process Optimization & enhancing business competitiveness. 

FIRST TIME RIGHT Methodologies.

Call Us Today!

M.S.; Metallurgical Engineering, University of Idaho, Moscow, Idaho, USA. December 1981. Extractive Metallurgy, Mineral Comminuition & Material processing.

Professional Engineer-in Training: #E2028, April, 2 1982; Idaho, USA. (State of Idaho, Professional Engineering Pre-qualification “Fundamentals of Engineering” examination).

Alberta, Canada: PE registration (#M93764) in progress. Passed the APPEGA Professional Practice Examination.

Lean Production Management: (JIT, Jidoka, TPM, 5S, Kanban, Kaizen Methodologies) ; December 2005. Certified by AOTS, Nagoya, Japan.

Six Sigma Black Belt: TQM, SQC & DOE Methodologies Certified by KPMG, Mumbai, India. October 2005.